How to Install a Glass Windshield on a Polaris Xpedition

Length: 5:17
Created: Dec 20, 2024

0:00 – Introduction

If you’re looking for a durable, high-quality windshield for your Polaris Expedition, SuperATV has you covered. This full glass windshield is designed with built-in vents for better airflow and offers compatibility with up to two windshield wipers, making it a versatile and functional upgrade for any rider.

In this installation guide, we’ll walk you through each step of the process to ensure you get the perfect fit. Whether you’re replacing an old windshield or upgrading for better visibility and protection, this guide will help you install your SuperATV windshield quickly and efficiently.

0:44 – Tools Needed for Installation

Before starting the installation, gather all the necessary tools to make the process smoother. Here’s what you’ll need:

• T40 Torx Bit – For removing and reinstalling factory hardware
• 5mm Allen Wrench – Used for mirror removal
• 10mm Wrench or Socket – For installing the wiper handle
• M8x20mm Allen Bolts and Nylock Nuts – Provided in the kit for mounting brackets
• Hex Head Hardware and Spacer – Used for securing the lower windshield brackets

Having these tools ready before you begin will help you complete the installation efficiently without unnecessary delays.

0:53 – Step 1: Apply the Bulb Seal to the Windshield

The first step in the installation process is applying the bulb seal to the windshield. This step is crucial for creating a tight, weatherproof seal that prevents water, dust, and debris from entering the cab.

If your windshield already has the bulb seal pre-installed, you can move on to the next step. Otherwise, carefully apply the seal along the edges, ensuring it is securely attached and evenly aligned for a proper fit.

0:59 – Step 2: Removing the Factory Headliner and Hardware

To install the new windshield, you’ll need to remove some factory components to gain access to the mounting points. By doing this, you create the space needed to properly secure the windshield and its supporting brackets. Follow these steps:

1. Use a T40 Torx bit to remove the screws holding the headliner in place.
2. Remove the 5mm Allen bolts securing the rearview mirror to the frame.
3. Carefully pull back the headliner just enough to allow access to the necessary mounting points.

1:34 – Step 3: Removing Roof Screws

Next, you’ll need to detach the roof from the frame to allow proper placement of the windshield. This step ensures that the windshield can be positioned correctly without interference from the roof structure.

1. Locate and remove the T40 screws that secure the roof in place.
2. Repeat the process on both sides of the machine.
3. Once all screws are removed, slightly lift the roof to provide space for the windshield installation.

1:43 – Step 4: Installing the Windshield

Now it’s time to mount the full glass windshield onto the machine. Proper positioning is crucial to avoid misalignment issues later in the installation.

1. Carefully lift the windshield and position it in place against the front frame of the Polaris Expedition.
2. Ensure that the edges are properly aligned with the frame before securing any hardware.
3. Double-check that the bulb seal sits flush against the frame for an airtight and secure fit.

1:52 – Step 5: Installing the Upper Bracket

To secure the top portion of the windshield, you’ll need to install the upper bracket. The upper bracket plays a key role in keeping the windshield stable and secure, so ensure all hardware is properly tightened.

1. Lift the roof slightly to align the bracket holes with the pre-drilled mounting points on the windshield.
2. Insert the M8x20mm Allen bolts through the bracket holes and secure them with the M8 Nylock nuts.
3. If your Polaris Expedition previously had a light bar installed, you may need to make adjustments to accommodate the bracket properly.

2:19 – Step 6: Installing Plugs and Additional Brackets

1. Locate the hole in the windshield where the provided plastic plug will be inserted.
2. Firmly press the plug into the hole until it is seated securely.
3. Move to the opposite side of the machine and repeat the upper bracket installation process.

Once both brackets are installed, the windshield should be held securely in place.

2:40 – Step 7: Installing the Manual Windshield Wiper

The manual wiper is a great addition to ensure clear visibility in rainy or muddy conditions. This step ensures that you have a functional manual wiper that enhances visibility during harsh weather conditions. Follow these steps to install it:

1. Remove the 10mm nut from the wiper handle.
2. Disassemble the washers and nuts, keeping track of their order.
3. Insert the handle through the designated hole in the windshield, ensuring the rubber washer is placed inside for a tight seal.
4. Secure the metal washer and nut on the outside of the windshield.
5. Adjust the handle position and tighten the nut to hold it in place.
6. Slide the wiper blade onto the handle and secure it with the previously removed 10mm nut.
7. Once secured, flip the wiper blade down onto the windshield and snap the plastic cover back into place.

4:03 – Step 8: Installing Lower Brackets for Added Stability

To further stabilize the windshield, lower brackets are installed. These brackets provide additional reinforcement, ensuring the windshield remains secure even during rough rides. 

1. Remove the factory hardware from the front lower plastic panel on both sides.
2. Align the SuperATV bracket with the existing threaded hole in the frame.
3. Insert the provided hex head hardware with a spacer and secure it into the threaded portion of the frame.
4. Insert the Allen hardware through the windshield hole and tighten it into the bracket.
5. Repeat the process on the opposite side of the machine.

4:52 – Step 9: Final Hardware Tightening & Reinstalling Panels

Now that all components are installed, it’s time for the finishing touches:

1. Go through all the installed hardware and fully tighten every bolt and nut.
2. Reinstall the factory panels and headliner that were removed earlier in the process.
3. Double-check for any loose connections or misalignments.

Once everything is secured, your SuperATV full glass windshield is officially installed and ready for action!

4:56 – Conclusion

Congratulations! You’ve successfully installed the SuperATV Full Glass Windshield on your Polaris Expedition. This upgrade provides better protection from the elements, improved airflow with built-in vents, and compatibility with dual wipers for maximum visibility.

If you found this guide helpful, make sure to like this video, comment with any questions or installation tips, and subscribe for more UTV upgrade guides. Click the link in the description to get your own SuperATV windshield today! Stay safe, ride hard, and we’ll catch you on the next one!